Full FAI vs partial (delta) FAI
A full FAI verifies every design characteristic on the drawing and every material, special process and functional test. A partial FAI, often called a delta FAI, covers only what the change could affect; the rest is carried over from the last approved full FAI, called the baseline. As one prime's supplier guide puts it: "On a Delta FAI only the changes are addressed."
Events that typically trigger a new FAI
Supplier guides that quote AS9102 list changes such as these. Check the exact wording in your licensed copy of the standard and in your customer's purchase order clauses.
- Design change that affects form, fit or function, for example a new drawing revision.
- A change in manufacturing source, process, inspection method, location of manufacture, tooling or materials that can potentially affect form, fit or function.
- Changes to NC programs used on machines, test stations or CMMs (some customers, such as Lockheed Martin's Q2A clause, name this explicitly).
- A lapse in production. AS9102 uses two years as the default interval unless the customer sets another. Some customers require a full FAI after a lapse, not a partial one.
- Nonconformances after the FAI whose cause is not special-cause variation (for example not a one-off tool breakage or power outage) can require a partial or full FAI under some customer clauses.
Customer clauses can be stricter than the standard
| Topic | Example customer requirement |
|---|---|
| Production lapse | Lockheed Martin Q2A (rev 12): full FAI when a lapse in production of over two years has occurred, regardless of the impact of the inactivity. |
| Sample size | Lockheed Martin Q2A: a partial FAI needs one part to show the change had no impact, or three parts for a Class I engineering change. |
| Notice | Lockheed Martin Q2A: notify the buyer's SQE in writing at least five business days before starting such changes. |
Examples quoted from the publicly posted clause; always use the revision called out on your own purchase order.
How to record a partial FAI on Form 1
Form 1 (Part Number Accountability) has a choice between Full FAI and Partial FAI. For a partial FAI you also give the baseline part number, including revision, of the FAI it builds on and the reason for the partial FAI. Forms 2 and 3 then list only the materials, processes and characteristics that were re-verified.
A quick checklist before you ship
- Is there an approved full FAI on file for this part number and revision?
- Has anything changed since then: drawing, source, process, inspection method, location, tooling, material or NC program?
- How long since the last production lot, and what lapse interval does your customer set?
- Does your customer's clause demand a full FAI for this trigger instead of a partial one?
- Have you ballooned and re-measured every characteristic the change could affect, and referenced the baseline FAI on Form 1?
Prepare the report in your browser
FAIR Lite collects AS9102 Form 1-3 data fields, including the full or partial FAI choice, checks each measured value against its tolerance and prints a PDF report. Data stays in your browser. The free version adds a watermark; Pro ($49 per month or $399 per year) removes it and saves unlimited reports. See also the AS9102 Form 3 field guide.
FAIR Lite is not the official IAQG form, and some customer portals only accept their own forms or file formats, so check your customer's requirements first. This page is general information, not legal, contractual or certification advice. Sources: Lockheed Martin Q2A clause rev 12; Kaman FAI Requirement Determination Questionnaire; General Dynamics OTS AS9102 FAI training (all publicly posted supplier documents).